DE102013203367A1 - INTERCHANGEABLE FORM INSERTS - Google Patents

Abstract

A mold core package for molding a mold with a removable insert contains a plurality of layered particle layers with a binder. The plurality of layered particle layers form forming model walls that generally define a base mold cavity and an insert mold cavity defining a mold surface. A lost displacement line extends through the insert cavity, closely conforming to the contours of the mold surface.

Description

The present invention relates generally to a molding assembly containing a base mold with interchangeable mold inserts.

Traditional shaping arrangements can be very large and complex. The exchange of forms can take a lot of time. Mold inserts serve as a quick alternative to traditional mold assemblies.

In accordance with one feature of the present invention, a mold core package for forming a mold with a removable insert includes a plurality of layered particle layers with a binder. The many layered particle layers form forming model walls that generally define a base mold cavity and an insert mold cavity defining a mold surface. A lost displacement line extends through the insert cavity, closely following the contours of the mold surface. According to another feature of the present invention, a mold core for molding a removable insert mold for use in a base mold contains a plurality of layered particle layers formed of a fine sand. A binder is deposited in thin coatings from a sand pressure device. The plurality of layered particle layers form lost mold core walls that define an insert mold cavity. A lost displacement line extends from the mold core walls near a molding surface. A core carrier spaces the lost displacement line from the mold core walls. According to still another feature of the present invention, a method of molding a component includes forming a base form with relay leads by forming a lost mandrel developed by printing a binder on many layers of fine particles. An insert mold is formed with conformal lines by forming a lost mandrel that is developed by printing a binder on many layers of fine particles. The insert defines a mold cavity. The insert mold is positioned in the base mold so that the relay lines are in fluid communication with the conformal lines. A temperature control station is connected to the base mold, which transmits a fluid through the relay lines and conformal lines. A moldable material is heated and injected into a mold cavity of the mold. The moldable material is cooled in the mold cavity.

Yet another feature of the present invention includes a squeegee device capable of printing many layers of binder on many layers of sand to form a mandrel. The mandrel is used to construct either an insert mold, a base mold or a mold used to make molded components. The insert mold or mold includes conformal conduits adapted to receive a heating fluid and a cooling fluid to assist in the formation of molded components within the insert mold or mold. The contoured lines closely follow a molding surface that is near a mold cavity of the insert mold or mold.

These and other features, objects, and devices of the present invention will be understood and appreciated by those skilled in the art upon reading the following specification, claims, and accompanying drawings.

In the drawings show:

1 a top perspective view of a rigid bounding box or work box prior to molding a mold core package by a sand pressure device;

2 a top perspective view of the rigid bounding box of 1 during spreading of the first layer of fine particles in the rigid bounding box;

3 a top perspective view of the rigid bounding box of 1 after several passes of a sand pressure device;

4 a top perspective view of the rigid bounding box of 1 just before a new layer of fine particles is to be distributed over the pressure surface of the rigid bounding box;

5 a top perspective view of the rigid bounding box of 1 while distributing a new layer of fine particles across the pressure surface of the rigid bounding box;

6 a top perspective view of the rigid bounding box of 1 after a full mold core has been printed in the stiff bounding box;

6A a side perspective view of the rigid bounding box of 1 containing the mandrels, loosening and removing excess unbound sand;

7 a top perspective view of unassembled mold components after they have been removed from the stiff bounding box;

7A a top perspective view of the assembled mold core of 7 ;

8th a view of a mold core of the 7A from above;

9 a perspective cross-sectional view from above along a line IX-IX of 8th ;

10 a side cross-sectional view of the mold core of the 8th along the line XX;

11 a top perspective cross-sectional view of a mold core package during the filling of molten metal in a molding region defined by the mold core package;

12 a top perspective cross-sectional view of the molding of a mold core package after the introduction of the molten metal in the mold core packet;

12A a side cross-sectional view of the mold core of the 12 ;

13 a top perspective view of the resulting mold, which is formed from the mold core package;

14A a top perspective cross-sectional view of an embodiment of a contoured line structure extending through a mold.

14B a top perspective cross-sectional view of another embodiment of a conformal line extending through a mold;

14C a top perspective cross-sectional view of another embodiment of a conformal line extending through a mold;

14D a top perspective cross-sectional view of another embodiment of a conformal line extending through a mold;

14E a top perspective cross-sectional view of another embodiment of a conformal line extending through a mold;

14F a top perspective cross-sectional view of another embodiment of a conformal line extending through a mold;

14G a top perspective cross-sectional view of another embodiment of a conformal line extending through a mold;

14H a top perspective cross-sectional view of another embodiment of a conformal line extending through a mold;

14I a top perspective cross-sectional view of another embodiment of a conformal line extending through a mold;

15A a top perspective cross-sectional view of an embodiment of a conformal container extending through a mold;

15B a perspective view from above of the contour near container and the mold of the 15A ;

15C a top perspective cross-sectional view of another embodiment of a conformal container extending through a mold;

15D a perspective view from above of the contour near container and the mold of the 15C ;

15E a top perspective view of another embodiment of a contoured container extending through a mold;

15F a top perspective view of yet another embodiment of a contoured container extending through a mold;

15G a top perspective view of yet another embodiment of a contoured container extending through a mold;

16 a top perspective view of the mold illustrating a first mold half prior to connection to a complementary second mold half;

16A a top perspective view of the first mold half and the second mold half of 16 after the connection;

17 a top perspective view of a molded component, which is removed from the first mold half and the second mold half;

18 a top perspective cross-sectional view of molding an insert molding tool in a mold core package;

19 a side cross-sectional view of the insert molding of the 18 ;

20 a top perspective cross-sectional view of the insert mold after removal from the mold core packet;

21 a top perspective view of the first and second insert molds prior to insertion into first and second base molds;

21A a top perspective cross-sectional view of the shaping arrangement of 21 ;

22 a perspective view from above of the shaping arrangement of 21 during molding of a component;

23 a perspective view from above of the shaping arrangement of 21 during removal of the molded component;

24 a schematic view of a temperature control station in conjunction with a shaping arrangement and introduction of a heating fluid in the shaping arrangement;

25 a schematic view of a temperature control station connected to a shaping arrangement and introduction of a cooling fluid in the shaping arrangement;

26 a schematic view of an embodiment of a heating system for use with a shaping assembly;

27 a schematic view of an embodiment of a cooling system for use with a mold of the present invention;

28 an exploded perspective view of a sand mold package from above, comprising a top box, a lower box and a core;

29 a top perspective view of the Sandformpakets the 28 wherein the core is inserted in the lower case;

30 a top perspective view of the Sandformpakets the 28 wherein the top and bottom boxes are juxtaposed to prepare pouring of a molten material;

31 a perspective view of a molded component, from the sand mold package of 28 is generated, wherein the sand mold package of 28 has broken away; and

32 a perspective view of the molded mold, as it through the sand mold package of 28 is produced.

For the purposes of the present description, the terms "upper,""lower,""right,""left,""rear,""front,""vertical,""horizontal," and derivatives thereof, refer to the invention as embodied in U.S. Patent Nos. 4,378,331; 1 is aligned. It should be understood, however, that the invention is susceptible to various alternative orientations unless expressly stated to the contrary. It should also be understood that the specific devices and processes illustrated in the accompanying drawings and described in the following description are simply exemplary embodiments of the inventive concepts defined in the appended claims. Therefore, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting unless the claims expressly determine otherwise.

With reference to the 1 - 27 is a mold core package 10 illustrated. The mold core package 10 is used to make a mold 12 to shape. The mold core package 10 contains a multitude of layered particle layers 14 that is a binder 16 to have. The multitude of layered particle layers 14 shape lost walls 18 , An elongated lost particle line 20 extends through the mold core package 10 and defines a contoured line 22 in the mold 12 , A mold cavity 26 is made of the multitude of layered particle layers 14 Are defined.

It is considered that the mold 12 could be used in any of a variety of shaping operations. Such molding operations may include injection molding, foam molding, blow molding, thermoforming, transfer molding, reaction injection molding, compression molding, extrusion, and so on. The mold 12 As set forth in the following description, is used for injection molding applications. However, one of ordinary skill in the art understands that the mold 12 that by using the mold core package 10 can be used for any of the above-mentioned molding applications.

Now, referring to the 1 - 6 a model box or work box 40 which is molded from any number of materials, including wood, metal, etc., under a printing device 42 positioned. The work box 40 defines a pressure range 44 , within which the mold core package 10 ( 8th ) from the plurality of layered particle layers 14 is built. The printing device 42 contains a funnel 46 and a separation channel 48 containing a thin layer of activated fine particles 50 , such as silica, sand, ceramic sand mixtures, etc., within the printing range 44 laid. The particles 50 can be of any size, including a diameter between 0.002 mm and 2 mm. The printing device 42 Also includes a binder removal apparatus or a binder dispenser 52 , As disclosed in detail below, the binder dispenser sprays 52 a thin layer of a binder or binder 16 in the form of a single layer of the desired mold core package 10 , The repetition of the stratification of sand and the spraying of binder 16 through the binder dispenser 52 on the fine particles 50 leads to the creation of three-dimensional (3D) mandrels 10 , The 3D mandrel models 10 are generated over a period of time sufficient for each thin layer of fine particles 50 to print. The produced mold core package 10 is finally used to the mold 12 used to make molded components.

With reference to 1 will initially be in one with the printing device 42 connected computer 60 running computer-aided design program (CAD) containing the desired shape of the final product into the CAD program of the printing device 42 fed. It is contemplated that CAD, or any other type of 3D modeling software, may be used to provide sufficient information for the 3D printing device 42 to deliver the desired mold core package 10 ( 8th ). Before activating the 3D printing device 42 becomes a predetermined amount of the fine particles 50 through a particle spout 62 together with an activation coating or activator 70 in the funnel 46 poured from an activator spout 72 is delivered. Although the illustrated embodiment has a fine sand as the fine particles 50 As mentioned above, the fine particles can be used 50 contain any of a variety of materials or combinations thereof. The fine particles 50 be in the funnel 46 with the activator 70 mixed. The mixture of fine particles 50 and activator 70 can from a stirrer 74 or other such stirring device so mixed that the fine particles 50 to be activated. After the fine particles 50 and the activator 70 thoroughly mixed, the fine particles become 50 to the separation channel 48 promoted. Well, referring to the 2 and 3 be after the fine particles 50 to the separation channel 48 were transported, the fine particles 50 through the separation channel 48 in a thin even layer over the print area 44 distributed. After putting in a thin layer on the printing area 44 in the work box 40 are dispersed, the activated fine particles 50 with the binder 16 sprayed. The binder 16 comes from the binder dispenser 52 containing a thin layer of the binder 16 in a model 80 sprays a first thin cross-sectional layer of the desired mandrel package 10 ( 8th ). After the binder 16 is sprayed, another mixture of fine particles 50 and activator 70 prepared and in the separation channel 48 poured. The separation channel 48 then gives another layer of activated fine particles 50 over the previously dispersed fine particle layer 50 in the work box 40 out. The binder dispenser 52 goes back over the print area 44 and spray a thin layer of the binder 16 in the model 80 comprising a second thin cross-sectional layer of the desired mandrel package 10 which is adjacent to the first thin cross-sectional layer. These steps are repeated many times until each cross-sectional layer of the mandrel package 10 has been printed ( 6 ). Using this mold core design technique, virtually any shape of mandrel package can be used 10 be formed. In addition, the mold core package 10 have internal structural features that otherwise can not be generated by other known methods. Specifically, the mold core package 10 be built to the multiplicity of lost particle lines 20 ( 6A ) contained in and around the mandrel package 10 extend. The multitude of lost particle lines 20 be from the binder 16 and the fine particles 50 in the same way as the mold core package 10 shaped. As will be disclosed in more detail herein, the plurality of lost particle conduits will become 20 used to make the contoured channels or lines 22 ( 13 ) to define the rapid heating and cooling of the mold 12 ( 13 ) during injection molding of the components.

Well, referring to the 7 and 7A It is also contemplated that any interlocking means may be used to connect components of a mandrel package. In the illustrated embodiment, a composite mandrel is 92 with a variety of components of a mold core package 93A . 93B . 93C and 93D suitable for insertion in a work box. In some cases, when large molds 12 ( 13 ), it may be that several components of a mold core package must be assembled to the molds 12 to shape. As shown, the components of a mandrel package become 93A . 93B . 93C and 93D using lost connectors 94 combined, which are suitable to fit in receiving slots 95 in each of the components of a mold core package 93A . 93B . 93C and 93D intervene. The components of a mold core package 93A . 93B . 93C and 93D otherwise act similar to the mold core package 10 , which is discussed in this disclosure.

As in the 8th - 11 shown contains the 3D mold core package 10 a mold surface 100 , which generally represents the shape of a component that will ultimately be formed. The mold core package 10 also contains the multitude of lost particle lines 20 , the contoured lines 22 ( 13 ) in the mold 12 define. The mold core package 10 Also has a shape that determines the size and positioning of contoured lines 22 which are elongated passages through the heating and cooling fluids during the molding of molded components in the mold 12 flow. At the same time contoured lines 22 over a shaping surface 160 ( 13 ) of what will ultimately be the mold component is arranged. The contoured lines 22 assist in heating and cooling the mold component during the molding process. As in the 9 and 10 shown is the mold core package 10 ready for the introduction of a molten material 110 , The molten material 110 may be any of a variety of metals, including cast iron or an alloy. core support 111 can at intermittent intervals in the mandrel package 10 be arranged. The core carrier 111 keep the lost particle lines 20 over the molding surface 100 in position. Both the mold core package 10 as well as the multitude of lost particle lines 20 are once used to a mold 12 manufacture. That is, the mold core package 10 and the multitude of lost particle leads 20 become generally during the production of the mold 12 destroyed after the molten material 110 in the mold core package 10 has solidified. An alloy, such as those described in US Provisional Patent Application No. 61 / 268,369 entitled "Casting or Slushing Method" and PCT International Publication No. WO-A-4/01947. WO 2010/144786 entitled "Slice Low Coefficient of Thermal Expansion Coefficient CTE with Textured Surface, and Method of Making and Using It", which are incorporated herein by reference, may be incorporated into the mandrel package 10 to be poured.

Now, referring to the 11 - 13 the mold 12 by pouring the molten material 110 in the mold core package 10 produced. The molten material 110 fills all empty space in and around the mold core package 10 , the lost walls 18 and lost particle lines 20 around. The molten material 110 may be part or all of the binder 16 in the thin particle layers 14 burn. After the introduction of the molten material 110 in the mold core package 10 becomes the mold core package 10 placed in an oven where the heat is the binder 16 in the mold core package 10 evaporated. The cast mold 12 is then by breaking up the lost walls 18 from the mold core package 10 Abandoned, and any remaining sand can be removed from the mold 12 be rinsed or washed. Likewise, the binder also volatilizes 16 in the lost particle lines 20 so that the contoured lines 22 Can be cleaned with a brush or a sprayer that contains the fine particles 50 from the contoured lines 22 washes.

It is further contemplated that thin boundary walls around the mold core package, such as that in FIG 11 shown mold core package 10 , can be printed. It is considered that the thin boundary walls largely correspond to the configuration of the in 11 shown work box 40 can reflect. It is possible to print the thin boundary walls using the above-mentioned sand printing process, although the mold core package 10 is printed. A molten material such as the molten material mentioned above 110 , can be poured inside the thin boundary walls surrounding the mandrel package 10 to be printed. In order for the thin boundary walls to withstand the casting process, a mold core package with thin boundary walls printed around the mold core package would be embedded in cast sand for additional retention. In this way, an additive manufacturing technique may be used to use boundary walls for confining and molding a cast component when held by cast sand. Further, a similar technique of printing thin guard boundary walls can be used to completely enclose a very fragile and complicated mold core package. In this way, it is contemplated that a thin barrier fenestration structure can be printed that completely surrounds a frangible mold core package to protect the mandrel assembly until needed for a molding process. The thin barrier wall structure may then be broken away for the foundry worker to retrieve the mandrel package.

As in the 12 - 13 shown, then let the molten material 110 Harden. The molten material 110 hardens to the mold 12 to shape. After curing, the mold core package 10 destroyed, and internal cavities are cleared away. After the mold 12 scrubbed and properly treated, the remaining finished mold 12 forming molded parts during an injection molding or other molding process. The mold 12 contains an injection port 120 for injecting a molding compound 122 ( 15B ) in the mold cavity 26 ( 16A ), which is between opposing molds 12 is defined. In addition, it should be noted that the contoured lines 22 in the mold 12 to be provided. The mold 12 represents only one half of a shaping arrangement 130 ( 16A ), the two molds 12 contains as the first and second mold halves 132 . 134 ( 16A ), which are used to form a molded component 140 be used.

Well, referring to the 14A - 14H can the lost particle leads 20 ( 12 ) are formed with different protuberances, after feeding molten material into the mold core package 10 irregular shapes in the contoured lines 22 define. Accordingly, the conformal lines 22 contain a variety of configurations and devices, such as vortex generating elements. As in 14A illustrates contains the contoured lines 22 a variety of ribs 141 , the wells 143 in the mold 12 define. The wells 143 can provide desired thermodynamic properties that effectively heat the molding compound prior to the molding process 110 or remove heat from an already formed component. In another embodiment, as in 14B shown, the ribs are 141 and depressions 143 built in a helical model, which further turbulence in the contour line 22 can produce when the mold 12 heated or cooled. Similar embodiments, as in the 14C - 14F shown, contain a diamond-shaped structure ( 14C ), a diamond-shaped structure which is helically configured ( 14D ), an oval structure ( 14E ) and an oval structure which is helically configured ( 14F ). In addition, the diameter of the conformal line can also be used 22 change so that the flow through the mold 12 increases or decreases while the heating / cooling fluid through the conformal lines 22 ( 14G ) goes. These and other variations of conformal lines 22 are as a result of the production of the mold 12 using a mold core package made by the 3D printing process described in detail herein. Traditional cooling ducts for forming tools have often been drilled, allowing for the possibility of irregularly shaped contiguous ducts 22 was made impossible. In addition, as in 14H It is considered that the longitudinal extent of the conformal lines 22 can be linear, curved, angled, etc. In addition, the contoured lines 22 be wavy and sections that are very close to the forming surface 160 ( 15A ), and contain other portions that are not near the forming surface 160 are, so that different areas of the contoured lines 22 a different thermal influence on the mold 12 and ultimately have the component that will be molded. As noted herein, these configurations are enabled by the 3D printing process described in detail herein.

Well, referring to the 15A - 15D it is considered that the contoured lines 22 with one or more conformal containers 145 be in touch or become part of them. Each contoured container 145 is formed by a lost displacement body, which with the mold core package 10 during the construction of the mold core package 10 is formed. The lost displacement body may contain various recesses, which after feeding molten material into the mold core package 10 irregular shapes in the contoured containers 145 define. The contoured containers 145 are suitable for a uniform flow of heating / cooling fluid through the mold 12 near the forming surface 160 to deliver that in the mold 12 is defined. The mold 12 Can handle many contoured containers 145 included, which is about the mold 12 extend. As in the 15C and 15D shown are regularly arranged columns 146 provided, which are intended to loads the mold 12 withstand, which are associated with injection molding pressures. The regularly arranged columns 146 ensure that the injection mold 12 not near one of the contoured containers 145 breaks or tears. In addition, the mold contains 12 partitions 139 that prevent in the mold cavity 26 ( 16A ) sprayed molding compound in the contour near container 145 or the contoured lines 22 penetrates. The contoured containers 145 can adopt a variety of constructions and at different distances to the forming surface 160 be arranged, depending on the desired thermal influence, the lines close to the contour 22 on the mold 12 and ultimately on the part to be molded. Additionally, it is contemplated that the contoured containers 145 through the mold 12 can be wavy through. More specifically, sections of contoured containers 145 closer to the forming surface 160 of the mold 12 as other sections of the contoured container 145 be provided, whereby areas are provided which have a higher thermal influence on the shaping surface 160 have as the areas of contoured containers 145 farther away from the shaping surface 160 are.

Well, referring to the 15E - 15G can use different vortex generating elements within the contoured container 145 be arranged to limit stagnation and the To improve turbulence of the heating / cooling fluid flowing through the component during the injection molding process. As in 15E shown are a number of ribs 147 Arranged at angles to each other, the flow between and around the ribs 147 to stimulate around. Alternatively, as in 15F shown is a variety of baffles 148 in intermittent positions within the contour near container 145 Arranging the flow of the container through the contoured container 145 flowing heating / cooling fluid and also the thermal influence of the heating / cooling fluid at the locations of the baffles 148 minimize. In yet another embodiment, as in 15G As shown, a plurality of intermittent protrusions extend 149 in the contoured container 145 , whereby the flow and the stagnation of heating / cooling fluid in konturnahen container 145 to be influenced. Although the illustrated projections 149 have a cylindrical structure, it is understood that the projections 149 could take many different forms. One of ordinary skill in the art will also understand that any one of a variety of different architectures in the mold 12 can be formed as a direct consequence of the fact that it is built by the 3D printing process disclosed herein. During the molding process, the vortex elements are defined by a depression in the mold core, which later during the preparation of the mold 12 is filled with the molten material.

Well, referring to the 16 and 16A is a first half of the mold 132 with a second mold half 134 which has previously been shaped and has a complementary shape. The first half of the mold 132 and the second half of the mold 134 make molds 12 Using the relative to the 1 - 14 be described in detail described printing technology. The mold cavity 26 between the first half of the mold 132 and the second mold half 134 represents the shape of the molded part 140 ( 17 ) that is to be formed. The first half of the mold 132 and the second half of the mold 134 are about pins 144 connected around corners of each of the first and second mold halves 132 . 134 are arranged and the first half of the mold 132 and the second half of the mold 134 fasten laterally (X and Y directions). At the same time a press attached 150 the first half of the mold 132 on the second half of the mold 134 in a vertical direction. After the first half of the mold 132 and the second half of the mold 134 attached to each other becomes the molding compound 122 through the injection opening 120 injected at high pressure. Consequently, the between the first half of the mold 132 and the second mold half 134 defined mold cavity 26 with the molding compound 122 filled. At the same time, a heating fluid 152 ( 24 and 25 ) in an entrance 153 through the conformal lines 22 pumped, the near the forming surface 160 the first half of the mold 132 and the second mold half 134 are arranged, and passes through an exit 155 out. The heating fluid 152 heats the forming surface 160 the first half of the mold 132 and the second mold half 134 what a correct flow of the molding material 122 into the mold cavity 26 caused. After the mold cavity 26 completely with molding compound 122 was filled, the heating fluid 152 from the contoured lines 22 emptied. The contoured lines 22 then use a cooling fluid 154 filled to the mold cavity 26 arranged molding compound 122 to cool quickly. It is considered that the cooling fluid 154 and the heating fluid 152 can be the same fluid. Alternatively, the cooling fluid 154 be a first fluid that works well in a cooled state, and the heating fluid 152 may be a second fluid that works well in a heated state. After a predetermined period of time, the first mold half 132 from the second mold half 134 separated, and the mold component 140 ( 17 ) is removed. The first half of the mold 132 and the second half of the mold 134 are now ready for recommissioning and introduction of additional molding compound 122 to more moldings 140 to shape.

Yet another embodiment of the present invention includes an insert molding assembly 168 ( 21 ), the first and second forms of use 170 . 172 has, also as a cavity tool 170 and core tool 172 known, which are suitable for first and second basic forms 174 . 176 clamp. As in the 18 - 20 Figure 1 illustrates the first and second embodiments 170 . 172 formed in a similar process as above with respect to the 1 - 14 outlined. The same 3D printing process is used, but the 3D printing process is used for the first and second insertions 170 . 172 instead of the finished mold 12 to shape. The first and second forms of use 170 . 172 provide a fast connection with the first and second basic forms 174 . 176 , thereby allowing a user the first and second uses 170 . 172 fast from the first and second basic forms 174 . 176 which improves the speed with which various mold components 140 can be produced in a molding plant. Contoured lines 22 and contoured containers 145 can work in either or both ways 170 . 172 be formed. It is also considered that the contoured lines 22 in fluid communication with the conformal lines 22 in the first and second basic forms 174 . 176 or with relay lines in the first and second basic forms 174 . 176 can stand. The contoured lines 22 Contoured container 145 and arbitrary relay lines are formed by forms of lost core parts, such as lost displacement lines and lost ones Displacement bodies in a mold core package 10 before the introduction of molten material into the mandrel package 10 prepared.

As in the embodiment of 21 - 23 The first and second embodiments are illustrated 170 . 172 for insertion into the first or second basic form 174 . 176 certainly. The first and second use 170 . 172 be with pins 180 aligned in alignment around corners of the first and second base shapes 174 . 176 are arranged. While the pins 180 in the in the 21 - 23 shown embodiment are suitable to in the first and second use form 170 . 172 to intervene, the present invention is not limited to this embodiment. The pencils 180 serve as a guide device that can guide the inserts, base shapes, inserts and base shapes, or the pins 180 can be completely removed. The first basic form 174 , first use 170 , second use 172 and second basic form 176 are then securely bonded, and molding compound 122 is through an entrance opening 179 in the first basic form 174 and by the first use 170 introduced. The molding material 122 takes the mold cavity 26 one between the first use 170 and the second form of use 172 is defined. The molding material 122 is then on the conformal lines 22 heated, which is a heating fluid 152 included in an entrance 182 , through the contoured lines 22 , and from an exit 184 a shaping surface 188 the first and second forms of use 170 . 172 is pumped out. After the molding material 122 completely within the mold cavity 26 has been pressurized, becomes cooling fluid 154 into the contoured lines 22 introduced to the molding compound 122 to cool or quench quickly, resulting in a cured molded part 140 is formed. The mold component 140 then gets out of the mold cavity 26 ( 23 ), and the first basic shape 174 , first use 170 , second use 172 and second basic form 176 are then reconnected and again with the molding compound 122 filled to additional molded parts 140 to shape.

Now in the 24 and 25 generally considered that the heating fluid 152 and the cooling fluid 154 , either through the mold 12 or the insert molding arrangement 168 (collectively referred to as the "shaping arrangement 200 From a temperature control system 202 to get redirected. The temperature control system 202 contains the heating fluid 152 and the cooling fluid 154 that with the mold 12 or the insert molding assembly 168 keep in touch. When the shaping arrangement 200 is to be heated, typically during the initial introduction of molding material 122 in the shaping arrangement 200 , opens a valve station 204 hot-side valves 206 that transfer the heating fluid 152 from a container 208 heated fluid to the shaping arrangement 200 allow. At the same time are cold side valves 210 that the transfer of the cooling fluid 154 from a container 212 cooled fluid to the shaping arrangement 200 Regulate, closed, leaving the cooling fluid 154 the shaping arrangement 200 can not reach. After the shaping arrangement 200 has reached the desired temperature for the desired period of time, the heating fluid 152 to the container 208 heated fluids returned, and the hot-side valves 206 that the fluid connection of the heating fluid 152 with the shaping arrangement 200 allow to be closed. At the same time, as in 25 shown are the cold side valves 210 between the container 212 cooled fluid and the shaping arrangement 200 were closed, open, leaving coolant 154 to the shaping arrangement 200 thus, by being able to flow through the molding compound 122 cools and the cured mold component 140 shaped.

26 illustrates an embodiment of a heating system 300 for use with the molding assembly as described above 200 , The heating system 300 contains a heating fluid line 302 passing through a dirt trap 304 goes away, the dirt or debris that is in the heating fluid 152 can be located. Then the heating fluid goes 152 through a degassing tank 306 , The degassing tank 306 removes unwanted gases and other impurities from the heating fluid 152 before it comes from a pump 308 to a heater 310 is moved. The heating fluid 152 is generally cooler than desired because the heating fluid 152 from the shaping arrangement 200 comes back where a heat transfer has taken place. Therefore, it is desirable to use the heating fluid 152 in the heater 310 to warm again. The heater 310 increases the temperature of the heating fluid 152 to a desired temperature, before the heating fluid 152 through a heat exchanger 312 let go of the regulation of the heat of the heating fluid 152 supported. The heat exchanger 312 is with a cooling water outlet 314 and a cooling water supply 316 coupled, which prevents the heat exchanger 312 reached too high a temperature. The heating fluid 152 then goes through first and second temperature sensors 317 . 318 indicating the temperature of the heating fluid 152 confirm before the heating fluid 152 through a flow meter 320 goes, a volumetric flow rate of the shaping arrangement 200 flowing heating fluid 152 supplies.

Now referring to 27 is a cooling system 400 illustrates that for a connection with the shaping arrangement 200 suitable is. The cooling fluid 154 goes through a dirt trap 402 and in a cooling tank 404 where the cooling fluid 154 is cooled to a desired temperature. The cooling fluid 154 is generally warmer than desired because the cooling fluid 154 from the shaping arrangement 200 comes back where heat from the shaping arrangement 200 and the molded part 140 on the cooling fluid 154 was transferred. Therefore, it is desirable to have the cooling fluid 154 in the cooling tank 404 to cool again. A temperature sensor 406 monitors the temperature in the cooling tank 404 , The cooling tank 404 gets from one in the cooling tank 404 arranged, sunk evaporator 408 cooled. The sunken evaporator 408 is connected to a refrigerant connected to a compressor 410 flows past, between high-pressure and low-pressure shutters 412 . 414 is arranged. After passing the compressor 410 the refrigerant is in a condenser 416 cooled. After leaving the condenser 416 the refrigerant goes to a collector 418 and a check valve 420 as well as a filter dryer 422 Passing before it on a sight glass 424 flows past where the refrigerant can be checked for color, condition, contamination, etc. The refrigerant then passes through an expansion valve 426 where the refrigerant cools quickly before it enters the cooling tank 404 entry. While the refrigerant passes through the cooling tank 404 goes, the refrigerant cools the cooling tank 404 and the contents of the cooling tank 404 so that the cooling fluid 154 in the cooling tank 404 is cooled to a desired temperature. The temperature of the cooling fluid 154 is from the temperature sensor 406 supervised. The cooling fluid 154 is then pumped out of the cooling tank 404 removed and in the shaping arrangement 200 and more specifically to the contoured lines 22 in the shaping arrangement 200 pushed.

Although the 26 and 27 Exemplary embodiments of the heating and cooling systems that may be used in conjunction with a mold, it is contemplated that other heating and cooling systems may be used in conjunction with the mold, and particularly the mold, insert molds and base molds, such as disclosed above.

Now, referring to 28 a further embodiment of the present invention, wherein a sand mold package 530 an upper mold or upper case 532 , a lower mold or lower case 534 and a core 522 contains. The sand mold package 530 consists entirely of mold and core components that are printed by a sand printer and then removed from the work box. The sand mold package 530 , as shown, is provided for casting a molten material in a similar manner as described above. Now, referring to the 29 and 30 the core 522 in a cavity 539 shown inserted on a surface of the lower box 534 is arranged, wherein the cavity 539 Forming a mold cavity, that of the union of the upper box 532 , the one cavity 537 has, and the sub-box 534 is defined. As in 30 shown is the sand mold package 530 with the top box 532 and the sub-box 534 stacked together fully assembled. As in 28 a cavity is formed by the union of cavities 537 . 539 generated in both the top box 532 as well as in the lower case 534 are arranged. As in the 28 - 30 shown are openings 536 and 538 on the surface of the top box 532 shown arranged. The opening 536 provides an access point for pouring a molten material into the sand mold package 530 as it is in 30 assembled. The access point 536 continues with a series of runners 541 connected, as in 28 shown, which allow the molten material from the top box 532 to the lower case 534 through the access point 536 to go. In this way fill the sprue distributor 541 by the union of the cavities 539 . 537 of the upper box 532 or the sub-box 534 generated mold cavity from bottom to top. As the molten material fills the mold cavity, excess molten material begins risers 538 to fill that on a surface of the upper box 532 are arranged. The riser pipes 538 Help the foundry worker know when the mold cavity of the sand mold package 530 has been filled, and also allows molten material to be available to fill any areas of the mold cavity as the molten material settles.

Once the molten material inside the sand mold package 530 has solidified, the sand mold package 530 broken away, as in 31 shown to be a cast component 540 expose. As in 32 shown is the cast component 540 shown with cast material that is used to access point 536 , the sprue distribution system 541 and the riser pipes 538 of the sand mold package 530 to fill in the 28 - 30 shown on a mold 542 hardened and solidified. These font configurations, which as 536A . 538A and 541A are displayed, machine or otherwise from the mold 542 removed to expose a tool ready for use in a molding operation.

The mandrel package and components contained therein, as well as the methods of making mold core package tools as disclosed herein, provide improved ability to uniformly cool all areas of a mold, thereby reducing the potential for warping, cracking, and the like. In addition, the accuracy associated with producing the dies from the printing process provides better quality, precision, and design flexibility of the component. The conformal lines enable improved thermal abilities. Many lines for heating and cooling are removed in favor of integrated conformal heating and cooling lines, which can be configured to meet the desired thermal load required to improve tool quality as well as tool and part quality. Further, the mold core package components and the tools made from the mold core package components can be designed to improve the cycle time, thereby increasing the component manufacturing capacity. Class A surfaces that provide a smooth glossy finish (ie piano black) can be designed without the need for any additional paint or varnish on the finished parts. Further, Class A surfaces having etched patterns may be developed by etching a pattern on a mold surface of a mold, resulting in a finished component having a pattern embossed thereon.

It will be understood by one of ordinary skill in the art that the structure of the described invention and other components is not limited to any particular material. Other exemplary embodiments disclosed herein may be formed from a wide variety of materials, unless otherwise described herein.

For purposes of this disclosure, the term "coupled" (in all its forms, coupled, coupled, coupled, etc.) generally means the connection of two components (electrical or mechanical) directly or indirectly to each other. Such a connection may be of fixed or movable nature. Such a connection may be obtained with the two components (electrical or mechanical) and any additional pontics integrally molded as a single integral body with each other or with the two components. Such a compound may be of a durable nature or of a removable or solvable nature, unless otherwise specified.

It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is only illustrative. Although only a few embodiments of the present innovations have been described in detail in this disclosure, it will be readily apparent to those skilled in the art that many changes are possible (eg, changes in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, Mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the recited subject matter. For example, elements shown as integrally formed may be constructed of many components, or elements shown as many components may be integrally molded, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or links or connectors or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be understood that the elements and / or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability in any of a wide variety of colors, textures, and combinations. Accordingly, it is intended that all such modifications be included within the scope of the present invention. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired embodiment and other exemplary embodiments without departing from the spirit of the present innovations.

It is understood that all of the processes or steps described herein within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are illustrative and not intended to be limiting.

It is also to be understood that variations and modifications to the above-mentioned structures and methods may be made without departing from the concepts of the present invention, and it is further understood that such concepts are covered by the following claims, unless These claims are expressly different.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2010/144786 [0064]

Claims (19)

A mandrel package for molding a mold with a removable insert, comprising: a plurality of layered particle layers containing a binder, wherein the plurality of layered particle layers form shaping model walls that generally define: a base mold cavity; and a mold cavity defining a mold surface; and a lost displacement line extending through the insert cavity and conforming closely to the contours of the forming surface. A mold core package according to claim 1, wherein the plurality of layered particle layers contains a fine-grained sand. A mandrel package according to claim 1, wherein parts of the lost displacement duct are supported over the forming surface of dies. A mandrel according to claim 1, further comprising: a model box located above the mold core package. A mandrel according to claim 1, further comprising: a lost displacement line extending through the base mold cavity. A mandrel according to claim 1, further comprising: Locking means located at corners in the forming model walls which allow connection of the mold core package to complementary mold core packages. Mold core for forming a removable insert mold for use in a base mold comprising: a plurality of layered particle layers formed from a fine sand and a binder deposited in thin coatings from a sand pressure device, the plurality of layered particle layers forming lost mold core walls defining an insert mold cavity; a lost displacement line extending from the mold core walls near a forming surface; and a core carrier that spaces the lost displacement line from the mold core walls. A mold core according to claim 7, wherein a substantial portion of the lost displacement duct is contoured to the shape of the insert cavity defined by the layered particle layers. A mandrel according to claim 7, further comprising: a lost displacement body coupled to the lost displacement line. The mold core of claim 9, wherein the plurality of layered particle layers also form lost base mold walls that generally define a base mold cavity, and wherein the lost displacement line extends from the lost insert mold walls to the lost base mold walls. A mandrel according to claim 7, further comprising: Locking means, which are arranged at corners in the mold core walls, which allow a connection of the mold core with complementary mold cores. A method of molding a component comprising: Forming a base form with relay leads by forming a lost mandrel developed by printing a binder on many layers of fine particles; Forming an insert mold with conformal lines by forming a lost mandrel developed by printing a binder on many layers of fine particles, the insert defining a mold cavity; Positioning the insert mold in the base mold such that the relay lines are in fluid communication with the conformal lines; Coupling a temperature control station to the base mold which carries a fluid through the relay lines and the contoured lines; Heating a moldable material that is injected into a mold cavity of the mold; and Cooling the moldable material in the mold cavity. The method of claim 12, further comprising: forming the conformal lines to substantially evenly follow the contours of a forming surface of the insert mold. The method of claim 12, further comprising: the use of a fine sand as fine particles. The method of claim 12, further comprising: forming an injection port through the base mold and the insert mold which introduces the moldable material into the mold cavity. The method of claim 12, wherein the step of heating a moldable material further comprises: rapidly heating the mold by flowing the fluid through the base mold and the insert mold, wherein the single fluid is in a heated state. The method of claim 12, wherein the step of cooling the moldable material further comprises: the rapid cooling of the mold by flowing the fluid through the base mold and the insert mold, wherein the single fluid is in a cooled state. The method of claim 12, further comprising: removing the insert mold from the base mold and replacing the insert mold with a replacement mold. The method of claim 12, wherein the step of coupling a temperature control station of the basic shape that transmits fluid through the relay lines and contoured lines further comprises: the connection of the fluid with both a cooling arrangement and with a heating arrangement.

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